2000 SUZUKI SWIFT sensor

ENGINE MECHANICAL (M13 ENGINE) 6A1-1
6F1
6A1
6G
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
10B
SECTION 6A1
ENGINE MECHANICAL (M13 ENGINE)
CONTENTS
GENERAL DESCRIPTION .............................6A1-2
ENGINE ...................................................... 6A1-2
ENGINE LUBRICATION ............................. 6A1-3
DIAGNOSIS ....................................................6A1-4
DIAGNOSIS TABLE .................................... 6A1-4
COMPRESSION CHECK ............................ 6A1-4
ENGINE VACUUM CHECK ........................ 6A1-6
OIL PRESSURE CHECK ............................ 6A1-7
VALVE LASH (CLEARANCE) ..................... 6A1-9
ON-VEHICLE SERVICE ...............................6A1-12
AIR CLEANER ELEMENT ........................ 6A1-12
AIR CLEANER ASSEMBLY AND
RESONATOR ........................................... 6A1-13
KNOCK SENSOR ..................................... 6A1-13
CYLINDER HEAD COVER ....................... 6A1-13
THROTTLE BODY AND INTAKE
MANIFOLD ................................................ 6A1-16
EXHAUST MANIFOLD .............................. 6A1-19OIL PAN AND OIL PUMP STRAINER ...... 6A1-21
TIMING CHAIN COVER ........................... 6A1-25
OIL PUMP ................................................. 6A1-30
TIMING CHAIN AND CHAIN
TENSIONER ............................................. 6A1-34
CAMSHAFT, TAPPET AND SHIM............ 6A1-39
VALVES AND CYLINDER HEAD ............. 6A1-44
PISTONS, PISTON RINGS,
CONNECTING RODS AND
CYLINDERS ............................................. 6A1-57
ENGINE MOUNTINGS ............................. 6A1-67
UNIT REPAIR OVERHAUL .......................... 6A1-68
ENGINE ASSEMBLY ................................ 6A1-68
MAIN BEARINGS, CRANKSHAFT AND
CYLINDER BLOCK................................... 6A1-73
REQUIRED SERVICE MATERIAL............... 6A1-85
TIGHTENING TORQUE SPECIFICATION... 6A1-86
SPECIAL TOOL ........................................... 6A1-87

WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System :
Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

ENGINE MECHANICAL (M13 ENGINE) 6A1-13
AIR CLEANER ASSEMBLY AND RESONATOR
REMOVAL
1) Disconnect negative cable at battery.
2) Disconnect IAT sensor coupler (1).
3) Disconnect breather hose (2) from cylinder head cover.
4) Remove air cleaner assembly (3), resonator (4) and their
hoses.
INSTALLATION
Reverse removal procedure for installation.
KNOCK SENSOR
Refer to “KNOCK SENSOR” in Section 6E.
CYLINDER HEAD COVER
REMOVAL
1) Disconnect negative cable at battery.
2) Remove air cleaner assembly, resonator and hoses by refer-
ring to “AIR CLEANER ASSEMBLY AND RESONATOR”.
3) Remove cylinder head upper cover (1).
4) Disconnect ignition coil couplers (1).
5) Remove ignition coil assemblies (2) with high-tension cord
(3).

6A1-16 ENGINE MECHANICAL (M13 ENGINE)
THROTTLE BODY AND INTAKE MANIFOLD
REMOVAL
1) Relieve fuel pressure according to fuel pressure relief proce-
dure described in Section 6.
2) Disconnect negative cable at battery.
3) Drain coolant by loosening drain plug (1).
1. Intake manifold 7. EVAP canister purge valve 13. Intake manifold mounting bolt (short) 19. Cushion
2. Intake manifold gasket 8. TP sensor 14. Intake manifold mounting bolt (long) 20. Fuel delivery pipe mounting bolt
3. Throttle body 9. IAC valve 15. EGR pipe gasket Tightening torque
4. Gasket 10. Fuel delivery pipe 16. O-Ring Do not reuse.
5. EGR pipe 11. Intake manifold stiffener 17. Grommet
6. MAP sensor 12. Intake manifold mounting nut 18. Injector assembly
WARNING:
To help avoid danger of being burned, do not remove
drain plug (1) and radiator cap while engine and radiator
are still hot. Scalding fluid and steam can be blown out
under pressure if plug and cap are taken off too soon.

ENGINE MECHANICAL (M13 ENGINE) 6A1-17
4) Remove air cleaner assembly, resonator and hoses by refer-
ring to “AIR CLEANER ASSEMBLY AND RESONATOR”.
5) Disconnect the following electric lead wires :
IAC valve (1)
TP sensor (2)
EVAP canister purge valve (3)
MAP sensor (4)
Fuel injector wire harness at couplers (5)
Each wire harness clamps
6) Disconnect accelerator cable from throttle body.
7) Disconnect the following hoses :
Brake booster hose (1) from intake manifold
PCV hose (2) from PCV valve
Canister purge hose (3) from EVAP canister purge valve
Water hoses (4) from throttle body and thermostat case
Fuel feed hose (5) from fuel delivery pipe
8) Remove fuel delivery pipe with fuel injectors from cylinder
head.
9) Disconnect EGR pipe (6) from EGR valve.
10) Remove intake manifold stiffener (1).

ENGINE MECHANICAL (M13 ENGINE) 6A1-19
EXHAUST MANIFOLD
REMOVAL
1) Disconnect negative cable at battery.
2) Disconnect heated oxygen sensor coupler (1) (if equipped)
and detach it from its stay.
3) Remove front bumper with front grille and heat insulator
panel by referring to Section 9.
4) Remove exhaust manifold cover (2).
1. Exhaust manifold 6. Exhaust manifold stiffener 11. Exhaust manifold mounting bolt
2. Exhaust manifold gasket 7. Gasket Tightening torque
3. Heated oxygen sensor (if equipped) 8. Exhaust manifold mounting nut Do not reuse.
4. Exhaust manifold cover 9. Exhaust manifold stiffener bolt
5. Engine hook 10. Exhaust pipe bolt
WARNING:
To avoid danger of being burned, do not service exhaust
system while it is still hot. Service should be performed
after system cools down.

ENGINE MECHANICAL (M13 ENGINE) 6A1-21
4) Install exhaust manifold cover (1) .
5) Connect heated oxygen sensor coupler (2) and fit coupler to
bracket securely (if equipped).
6) Install heat insulator panel and front bumper with front grille
by referring to Section 9.
7) Connect negative cable at battery.
8) Check exhaust system for exhaust gas leakage.
OIL PAN AND OIL PUMP STRAINER
REMOVAL
1) Disconnect negative cable at battery.
2) Disconnect heated oxygen sensor coupler and detach it from
its stay.
3) Remove oil level gauge.
[A] : Sealant application amount 3. O-ring 8. Oil pan nut
“a” : 3 mm (0.12 in.) 4. Gasket 9. Oil pan bolt
“b” : 2 mm (0.08 in.) 5. Drain plug Tightening torque
1. Oil pan
: Apply sealant 99000-31150 to mating surface.6. Strainer bolt Do not reuse.
2. Strainer 7. Bracket bolt

ENGINE MECHANICAL (M13 ENGINE) 6A1-25
TIMING CHAIN COVER
REMOVAL
1) Disconnect negative cable at battery.
2) Disconnect the following electric lead wires, and remove
these connector bracket.
CMP sensor
Heated oxygen No.1 and No.2 sensors
Engine oil pressure switch
[A] : Sealant application
amount
3. Oil seal
: Apply engine oil to oil seal lip.8. Oil pan mounting bolt
“a” : 3 mm (0.12 in.) 4. Timing chain cover
: Apply sealant 99000-31140 to the mating surface
of cylinder and cylinder head.
: Apply sealant 99000-31150 to the mating surface
of timing chain cover referring to the figure of Step
1) in INSTALLATION.9. Oil pan mounting nut
“b” : 2 mm (0.08 in.) 5. Pin 10. Cylinder head cover
: Apply sealant 99000-31150 to the sealing
point for timing chain cover mating surface
and cylinder head gasket sealing point.
Refer to “CYLINDER HEAD COVER
INSTALLATION”.
1. Crankshaft pulley bolt 6. Cylinder head gasket Tightening torque
2. Crankshaft pulley 7. Timing chain cover mounting bolts Do not reuse.

ENGINE MECHANICAL (M13 ENGINE) 6A1-45
4) Drain coolant by loosening drain plug (1).
5) Remove air cleaner assembly (1), resonator and hoses (2)
referring to “AIR CLEANER ASSEMBLY AND RESONA-
TOR”.
6) Disconnect the following electric lead wires :
EGR valve (if equipped)
IAC valve (1)
TP sensor (2)
MAP sensor (3)
CMP sensor
ECT sensor
EVAP canister purge valve (4)
Injectors (5)
Ignition coils
Heated oxygen sensors
Ground terminal from exhaust manifold
Each wire harness clamps
7) Remove heated oxygen sensor bracket from timing chain
cover and detach heated oxygen sensor couplers from its
bracket.
8) Disconnect accelerator cable from throttle body.
9) Disconnect the following hoses :
Brake booster hose (1) from intake manifold
Canister purge hose (2) from EVAP canister purge valve
Fuel feed and return hose (3) from each pipe
Water hose (4) from thermostat case
Heater inlet hose (5) from its pipe WARNING:
To help avoid danger of being burned, do not remove
drain plug (1) and radiator cap while engine and radiator
are still hot. Scalding fluid and steam can be blown out
under pressure if plug and cap are taken off too soon.